Note: Descriptions are shown in the official language in which they were submitted.
CA 02687658 2009-11-18
WO 2009/005915
PCT/US2008/064953
SPRAY DEVICE HAVING A PARABOLIC FLOW SURFACE
BACKGROUND
[0001] This
section is intended to introduce the reader to various aspects of art that
may be related to various aspects of the present invention, which are
described and/or
claimed below. This discussion is believed to be helpful in providing the
reader with
background information to facilitate a better understanding of the various
aspects of
the present invention. Accordingly, it should be understood that these
statements are
to be read in this light, and not as admissions of prior art.
[0002] Spray
coating devices, often described as spray guns, are used to spray a
coating onto a wide variety of work products. In addition, there are a variety
of
different types of spray coating devices. Some spray coating devices are
manually
operated, while others are operated automatically. One example of a spray
coating
device is a rotary atomizer. Rotary atomizers utilize a spinning disc or bell
to atomize
a coating material, such as paint, by centrifugal action. An electrostatic
charge may
be imparted to the atomized paint particles with a small amount of shaping air
to
project the particles forward toward the object that is being coated. Rotary
atomizers
may generally have a splash plate to direct fluids toward the surface of the
bell, where
the fluid is dehydrated as it flows to the edge of the bell. In some cases,
inadequate
dehydration may cause variations in the spray coating color. In addition,
fluid and/or
particulate matter may become lodged between the splash plate and the bell
cup,
causing irregularities in the spray coating and difficulty in cleaning the
spray device.
BRIEF DESCRIPTION
[0003]
Certain aspects commensurate in scope with the originally claimed
invention are set forth below. It should be understood that these aspects are
presented
merely to provide the reader with a brief summary of certain forms the
invention
might take and that these aspects are not intended to limit the scope of the
invention.
Indeed, the invention may encompass a variety of aspects that may not be set
forth
below.
1
CA 02687658 2009-11-18
WO 2009/005915
PCT/US2008/064953
[0004] A spray coating device, in one embodiment, includes a bell cup having a
generally parabolic flow surface. A spray coating system, in another
embodiment,
includes a bell cup having a central opening, an outer edge downstream from
the
central opening, and a flow surface between the central opening and the outer
edge.
The flow surface has a flow angle relative to a central axis of the bell cup,
and the
flow angle decreases in a flow path along the flow surface. A method for
dispensing a
spray coat, in another embodiment, includes flowing fluid from a central
opening in a
bell cup to an outer edge of the bell cup at least partially along a generally
parabolic
path.
DRAWINGS
[0005] These and other features, aspects, and advantages of the present
invention
will become better understood when the following detailed description is read
with
reference to the accompanying drawings in which like characters represent like
parts
throughout the drawings, wherein:
[0006] FIG. 1 is a diagram illustrating an embodiment of a spray coating
system
having a spray coating device with a parabolic flow surface;
[0007] FIG. 2 is a flow chart illustrating an embodiment of a spray coating
process
using a spray coating device having a parabolic flow surface;
[0008] FIG. 3 is a perspective view of an embodiment of a spray coating device
having a parabolic flow surface;
[0009] FIG. 4 is a front view of an embodiment of the spray coating device of
FIG.
3;
[0010] FIG. 5 is a side view of an embodiment of the spray coating device of
FIG.
3;
[0011] FIG. 6 is a cross-sectional view of an embodiment of the spray coating
device of FIG. 4 taken along line 6-6;
2
CA 02687658 2009-11-18
WO 2009/005915
PCT/US2008/064953
[0012] FIG. 7
is a partial cross-sectional view of an embodiment of the spray
coating device of FIG. 6 taken along line 7-7;
[0013] FIG. 8
is a partial view of a serrated edge of an embodiment of the spray
coating device of FIG. 7 taken along line 8-8;
[0014] FIG. 9
is a cross-sectional view of an embodiment of a bell cup having a
parabolic flow surface for use with a spray coating device;
[0015] FIG.
10 is a cross-sectional view of a splash plate for use with a spray
coating device; and
[0016] FIGS.
11-13 are cross-sectional views of embodiments of bell cups for use
with various spray coating devices.
DETAILED DESCRIPTION
[0017] One or more specific embodiments of the present invention will be
described below. In an effort to provide a concise description of these
embodiments,
not all features of an actual implementation are described in the
specification. It
should be appreciated that in the development of any such actual
implementation, as
in any engineering or design project, numerous implementation-specific
decisions
must be made to achieve the developers' specific goals, such as compliance
with
system-related and business-related constraints, which may vary from one
implementation to another. Moreover, it should be appreciated that such a
development effort might be complex and time consuming, but would nevertheless
be
a routine undertaking of design, fabrication, and manufacture for those of
ordinary
skill having the benefit of this disclosure.
[0018] A
rotary atomizer spray coating device, in certain embodiments, has a bell
cup with a curved flow surface, such as a generally parabolic flow surface, in
a flow
path for fluid flowing downstream to create a spray. In other words, an angle
tangent
to the flow surface progressive changes along the flow path, for example, in a
completely continuous manner, in small steps, or with compounded curves. The
3
CA 02687658 2009-11-18
WO 2009/005915
PCT/US2008/064953
curved flow surface, e.g., generally parabolic or with curves approximating a
parabolic curve, is contrastingly different from a conical flow surface in
terms of
function, way, and result associated with the fluid flow, spray
characteristics, color
matching, and cleaning, among other things. For example, the generally
parabolic
flow surface provides additional surface area for dehydration of coating
fluids, thereby
improving color matching as compared to traditional bell cups, for example, by
affording capability for higher wet solids content. In addition, the coating
fluid
accelerates along the generally parabolic flow surface, resulting in the fluid
leaving
the bell cup at a greater velocity than in traditional bell cups. Furthermore,
a splash
plate disposed adjacent the bell cup, in certain embodiments, is designed such
that
fluid accelerates through an annular area between the splash plate and the
generally
parabolic flow surface. This acceleration may substantially reduce or
eliminate low-
pressure cavities in which fluid and/or particulate matter may be trapped,
resulting in
an even application of coating fluid and more effective cleaning of the bell
cup as
compared with traditional bell cups.
[0019] FIG. 1 is a flow chart illustrating an exemplary spray coating
system 10,
which generally includes a spray coating device 12 having a curved flow
surface (e.g.,
a generally parabolic flow surface) for applying a desired coating to a target
object 14.
Again, as mentioned above and discussed in further detail below, the curved
flow
surface of the spray coating device 12 provides significant advantages over
existing
conical flow surfaces. For example, the function of the curved flow surface
may
include increasing dehydration of the fluid, accelerating the fluid flow as it
flows
downstream, and progressively increasing force on the fluid as it flows
downstream.
The increased dehydration is provided by the increased surface area attributed
to the
curved geometry as compared to a conical geometry. In addition, the thickness
of the
sheet of fluid flowing across the curved flow surface decreases from the
center of the
surface outward. The accelerated fluid flow is provided by the progressively
changing
angle of the fluid flow attributed to the curved geometry as compared to a
conical
geometry. The progressively increasing force is also provided by the
progressively
changing angle of the fluid flow attributed to the curved geometry as compared
to a
conical geometry. The thickness of the fluid sheet as it leaves the edge of
the curved
4
CA 02687658 2009-11-18
WO 2009/005915
PCT/US2008/064953
flow surface may be greater than that of a traditional conical bell cup,
however the
greater force and/or greater acceleration of the fluid flowing along and
leaving the bell
cup provides improved color matching, improved atomization, and reduced
clogging
(e.g., the system is cleaner) as compared to traditional conical bell cups.
100201 The spray coating device 12 may be coupled to a variety of supply and
control systems, such as a fluid supply 16, an air supply 18, and a control
system 20.
The control system 20 facilitates control of the fluid and air supplies 16 and
18 and
ensures that the spray coating device 12 provides an acceptable quality spray
coating
on the target object 14. For example, the control system 20 may include an
automation system 22, a positioning system 24, a fluid supply controller 26,
an air
supply controller 28, a computer system 30, and a user interface 32. The
control
system 20 also may be coupled to a positioning system 34, which facilitates
movement of the target object 14 relative to the spray coating device 12.
Accordingly,
the spray coating system 10 may provide synchronous computer control of
coating
fluid rate, air flow rate, and spray pattern. Moreover, the positioning system
34 may
include a robotic arm controlled by the control system 20, such that the spray
coating
device 12 covers the entire surface of the target object 14 in a uniform and
efficient
manner. In one embodiment, the target object 14 may be grounded to attract
charged
coating particles from the spray coating device 12.
[0021] The spray coating system 10 of FIG. 1 is applicable to a wide
variety of
applications, fluids, target objects, and types/configurations of the spray
coating
device 12. For example, a user may select a desired object 36 from a variety
of
different objects 38, such as different material and product types. The user
also may
select a desired fluid 40 from a plurality of different coating fluids 42,
which may
include different coating types, colors, textures, and characteristics for a
variety of
materials such as metal and wood. As discussed in further detail below, the
spray
coating device 12 also may comprise a variety of different components and
spray
formation mechanisms to accommodate the target object 14 and fluid supply 16
selected by the user. For example, the spray coating device 12 may comprise an
air
atomizer, a rotary atomizer, an electrostatic atomizer, or any other suitable
spray
formation mechanism.
CA 02687658 2009-11-18
WO 2009/005915
PCT/US2008/064953
[0022] The spray coating system 10 may be utilized according to an exemplary
process 100 for applying a desired spray coating to the target object 14, as
illustrated
in FIG. 2. The process 100 begins by identifying the target object 14 for
application
of the desired fluid (block 102). The process 100 then proceeds by selecting
the
desired fluid 40 for application to a spray surface of the target object 14
(block 104).
The spray coating device 12 may be configured for the identified target object
14 and
selected fluid 40 (block 106). As the spray coating device 12 is engaged, an
atomized
spray of the selected fluid 40 is created (block 108). The spray coating
device 12 may
then apply a coating of the atomized spray to the desired surface of the
target object
14 (block 110). The applied coating is then cured and/or dried (block 112). If
an
additional coating of the selected fluid 40 is requested at a query block 114,
then the
process 100 proceeds through blocks 108, 110, and 112 to provide another
coating of
the selected fluid 40. If an additional coating of the selected fluid is not
requested at
query block 114, then the process 100 proceeds to a query block 116 to
determine
whether a coating of a new fluid is needed. If a coating of a new fluid is
requested at
query block 116, then the process 100 proceeds through blocks 104, 106, 108,
110,
112, and 114 using a new selected fluid for the spray coating. If a coating of
a new
fluid is not requested at query block 116, then the process 100 is finished
(block 118).
[0023] A perspective view of an exemplary embodiment of a spray device 200 for
use in the system 10 and process 100 is illustrated in FIG. 3. The spray
device 200
includes a rotary atomizer 202 and an electrostatic charge generator 204. The
rotary
atomizer 202 includes at its front a bell cup 206 having an atomizing edge 208
and a
flow surface 210. As mentioned above and discussed in detail below, the flow
surface
210 advantageously includes a curved flow surface, such as a generally
parabolic flow
surface, as opposed to a substantially or entirely conical flow surface. A
splash plate
212 is disposed within the bell cup 206. The electrostatic charge generator
204
includes a high voltage ring 214, high voltage electrodes 216, and a connector
218 for
connection to a power source. A neck 220 of the spray device 200 includes at
its
distal end air and fluid inlet tubes and a high voltage cable inlet. FIGS. 4
and 5 are
front and side views, respectively, of an embodiment of the spray device 200
of FIG.
3.
6
CA 02687658 2009-11-18
WO 2009/005915
PCT/US2008/064953
[0024] FIG. 6
is a cross-sectional view of an embodiment of the spray device 200
taken along line 6-6 of FIG. 4. The rotary atomizer 202 includes an atomizer
spindle
222 and a spindle shaft 224. An air turbine rotates the spindle shaft 224
within the
spindle 222. The bell cup 206 is coupled to a proximal end of the spindle
shaft 224
such that rotation of the spindle shaft 224 also rotates the bell cup 206.
When fluid
enters the rotating bell cup 206, the fluid travels along the flow surface 210
(e.g.,
curved, parabolic, or substantially continuously changing) and is atomized
into fluid
particles as it leaves the atomizing edge 208.
[0025] A
fluid tube 226 is disposed within the spindle shaft 224 for supplying
fluids, such as the desired coating fluid 40, to the bell cup 206. The
illustrated fluid
tube 226 is not coupled to the spindle shaft 224 and does not rotate with
respect to the
spray device 200. One or more fluid passageways 228 may be disposed within the
fluid tube 226 and may extend to one or more fluid supplies. In some
instances, it
may be desirable to clean the bell cup 206 without purging the system.
Accordingly,
the fluid passageways 226 may include separate passageways for the coating
fluid 40
and a solvent. In addition, a solvent nozzle 230 is located adjacent to the
bell cup 206
and is configured to direct a spray of cleaning solvent to the exterior of the
bell cup
206. A fluid valve 232 is disposed within the coating fluid passageway 228 and
is
configured to selectively enable flow of the coating fluid 40 when air is
supplied to
the air turbine. That is, the valve 232 opens when rotation of the spindle
shaft 224 and
the bell cup 206 is activated.
[0026] Air is
supplied to the turbine via one or more air passageways 234. The air
passageways 234 also supply air to shaping air jets 236. The shaping air jets
236 are
configured to direct the fluid particles toward the target object 14 as the
particles leave
the atomizing edge 208 of the bell cup 206. In addition, the high voltage
electrodes
216 are configured to generate a strong electrostatic field around the bell
cup 206.
This electrostatic field charges the atomized fluid particles such that the
particles are
attracted to the grounded target object 14. The high voltage electrodes 216
are
energized via the high voltage ring 214. The connector 218 is configured to
couple
the high voltage ring 214 to a high voltage cable. The high voltage cable may
exit the
neck 220 at an opening 240 to couple with the connector 218.
7
CA 02687658 2009-11-18
WO 2009/005915
PCT/US2008/064953
[0027] FIG. 7 is a close-up cross-sectional view of an embodiment of the
spray
coating device 200 taken along line 7-7 of FIG. 6. A fluid tip 242 is
connected to a
proximal end of the fluid tube 226. One or more fluid inlets 244 in the fluid
tip 242
are connected to the one or more fluid passageways 228 in the fluid tube 226.
Fluid
exits the tip 242 at a fluid outlet 246 and impacts a rear surface 248 of the
splash plate
212. The rear surface 248 of the splash plate 212 directs the fluid radially
outward
toward the flow surface 210. As the bell cup 206 rotates, the fluid travels
along the
flow surface 210 to the atomizing edge 208. As discussed further below, the
flow
path between the rear surface 248 of the splash plate 212 and the flow surface
210
(e.g., curved, parabolic, or substantially continuously changing) may converge
the
fluid flow that is flowing toward the edge 208, thereby reducing the potential
for low
pressure zones, clogging, and so forth. Thus, the converging flow may ensure
that the
spray coating device 200 remains clean, thereby reducing downtime for cleaning
or
repair due to debris buildup.
[0028] In one embodiment, the atomizing edge 208 may include serrations 250,
as
illustrated in FIG. 8. As the bell cup 206 rotates, fluid travels along the
flow surface
210 generally in the direction of arrows 252. As the fluid reaches a tapered
end 254 of
the serrations 250, separate fluid paths 256 are formed between the serrations
250.
The serrations 250 may increase in width and height away from the tapered ends
254,
decreasing the width of the fluid paths 256. As a result of the serrations
250, the fluid
may tend to leave the edge 208 of the bell cup 206 traveling generally in a
direction
along the fluid paths 256. Other structures may also be utilized, such as, for
example,
ridges or grooves. Moreover, as mentioned above, the curved geometry (e.g.,
generally parabolic) of the flow surface 210 may accelerate the fluid flow and
increase
the force applied to the fluid in the path toward the edge 208. As a result,
the
increased acceleration and force on the fluid flow may improve the
effectiveness of
the serrations 250, which then improves atomization, color matching, and so
forth.
[0029]
Referring now to FIG. 9, if the bell cup 206 does not have a sufficient
rotational velocity, fluid may enter the bell cup 206 at a greater rate than
it can be
dispersed. Accordingly, there is provided a flow cavity 258 having holes 260
which
are in fluid communication with the exterior of the bell cup 206 via channels
262.
8
CA 02687658 2009-11-18
WO 2009/005915
PCT/US2008/064953
1 Excess fluid exiting the fluid outlet 246 may travel to the
flow cavity 258 and out of
the bell cup 206 rather than backing up in the fluid tube 226.
[0030] In the exemplary embodiment illustrated in FIG. 9, the
flow surface 210 of
the bell cup 206 extends from a central opening 263 to the atomizing edge 208.
The
illustrated flow surface 210 has a curved shape, which is a generally
parabolic shape.
That is, the flow surface 210 may be defined by a parabolic curve rotated
about a
center axis 264. However, a variety of other curved surfaces also may be used
for the
flow surface 210 of the bell cup 206. It should be noted that the flow surface
210 is at
least partially, substantially, or entirely curved, but is not substantially
or entirely
conical. For example, the flow surface 210 may be 10, 20, 30, 40, 50, 60, 70,
80, 90,
95, or 100 percent curved in a path extending between the central opening 263
and the
edge 208. The curved geometry, e.g., parabolic, may be defined as a single
continuous curve, a compounded curve, a series of curves in steps one after
another
(e.g., stepwise curve), and so forth. For example, each step may be less than
1, 2, 3, 4,
5, 6, 7, 8, 9, 10, or possibly a greater percent of the distance between the
opening 263
and the edge 208.
[0031] In certain embodiments, an angle of the flow surface
210 relative to the
central axis 264 decreases progressively from the center of the bell cup 206
to the
atomizing edge 208. This angle decrease can be seen in angles a and 13,
defined by
lines 266 and 268, respectively, with relation to the center axis 264. The
line 266 is
tangential to the flow surface 210 near the splash plate 212, and the line 268
is
tangential to the flow surface 210 near the atomizing edge 208. The curved
geometry
(e.g., parabolic) of the flow surface 210 provides a greater surface area as
compared to
traditional bell cups (e.g., conical) for a given bell cup diameter. This
improved
surface area provides additional dehydration surface for color matching of
waterborne
coatings by affording capability for higher wet solids content. In addition,
the
parabolic flow surface 210 results in increasing force on the fluid as it
travels to the
atomizing edge 208. This increasing force enables the fluid to leave the
atomizing
edge 208 at a greater velocity than in traditional bell cups. In addition, in
bell cups
with serrations 250 at or near the atomizing edge 208, the increasing force
enables the
fluid to flow through the serrations 250 at a greater velocity. The curved
flow surface
9
CA 02687658 2009-11-18
WO 2009/005915
PCT/US2008/064953
210 may also result in a thicker sheet of coating at the atomizing edge 208,
therefore
the curve of the parabola may be determined by balancing the desired sheet
thickness
against dehydration and fluid velocity requirements. The parabolic flow
surface 210
may be manufactured in a stepwise manner such that each step is angled in
relation to
the previous step. That is, the flow surface 210 may be a number of stepwise
surfaces
having variably changing angles with respect to the center axis 264.
[0032] In addition, the splash plate 212 and bell cup 206 are designed such
that
there is a converging annular passageway 269 between the rear surface 248 and
the
flow surface 210. The convergence of the fluid flow may be a constant rate of
convergence or it may be an increasing rate of convergence in various
embodiments
of the spray coating device. As illustrated, a distance 270 near the center
axis 264
between the rear surface 248 and the flow surface 210 is greater than a
distance 272
away from the center axis 264 between the rear surface 248 and the flow
surface 210.
This convergence results in an accelerating fluid flow through the annular
passageway. The acceleration may be a constant rate of acceleration or it may
be an
increasing rate of acceleration. In addition, in the illustrated embodiment,
there are no
flat sections on either the flow surface 210 or the rear surface 248, such
that there are
no low-pressure cavities in which fluid and/or particulate matter may be
trapped. As a
result, the coating fluid may be applied at a generally even velocity, and the
bell cup
206 may be cleaned more effectively than a traditional bell cup. The splash
plate 212
further includes small holes 274 through which fluid may flow. A small amount
of
fluid may seep through the holes 274 to wet a front surface 276 of the splash
plate 212
so that specks of coating fluid do not dry on the splash plate 212 and
contaminate the
applied coating.
[0033] A more detailed view of the splash plate 212 is illustrated in FIG.
10. The
splash plate 212 includes two sections, a disc section 278 and an insert
section 280.
The sections 278 and 280 are held together by connectors 282. The connectors
282
may include, for example, pins or screws. The insert section 280 is configured
to be
inserted into the central opening 263 in the bell cup 206. A locking ring 284
secures
the splash plate 212 to the bell cup 206.
CA 02687658 2012-10-16
[0034] A similar embodiment of the bell cup is illustrated in FIG. 11. In a
bell cup
286, the generally parabolic flow surface 210 extends to a flip edge 288 which
extends
to the atomizing edge 208. A junction region 289 connects the flow surface 210
to the
flip edge 288. An angle y is defined by a line 290 tangential to the flip edge
288 and
the central axis 264. As can be seen in FIG. 11, the angle y is significantly
smaller
than the angle p. In addition, the difference between the angles 13 and y is
much larger
than the difference between the angles a and p. This is due to a greater
curvature in
the junction region 289 than in the flow surface 210. The flip edge 288 may
have a
constant angle relative to the center axis 264 or may have a progressively
decreasing
angle similar to the flow surface 210. As fluid reaches the junction region
289, the
increased curvature accelerates the fluid at a greater rate as compared to the
flow
surface 210. Accordingly, fluid may leave the atomizing edge 208 with a
greater
velocity when the flip edge 288 is present, as in the bell cup 286, than when
the flip
edge is not present, as in the bell cup 206 of FIG. 9.
[0035] FIGS. 12 and 13 illustrate alternative embodiments of the bell cup and
splash plate. A cross-sectional view of a bell cup 292 and a splash plate 294
are
illustrated in FIG. 12. The bell cup 292 has a generally parabolic flow
surface 296. A
rear surface 298 of the splash plate 294 has a generally concave shape from a
center
point 300 to an edge 302. As with the embodiment illustrated in FIG. 9, the
splash
plate 294 and the bell cup 292 are configured such that the rear surface 298
and the
flow surface 296 converge in the flow path away from the center point 300 of
the
splash plate 294. In addition, a distance 304 between the edge 302 of the
splash plate
294 and the flow surface 296 is greater than the distance 272 in FIG. 9,
allowing for a
greater flow rate of fluid. In a similar embodiment of the bell cup,
illustrated in FIG.
13, a bell cup 306 has a flip edge 308.
[0036] While only certain features of the invention have been illustrated and
described herein, many modifications and changes will occur to those skilled
in the
art. It is, therefore, to be understood that the appended claims are intended
to cover all
such modifications and changes as fall within the scope of the appended
claims.
11
